Ohmic Liquid Heater With Serpentine Flow for On-Demand Hot Water
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Solution Overview
Problem
Existing systems for providing hot water in commercial beverage production suffer from inefficiencies due to continuous heating, thermal losses, scaling, and dry fire failures, which are exacerbated by electrical resistance heating elements.
Innovation Solution
A liquid heater assembly that heats water on demand using a serpentine or spiral fluid path with electrodes, eliminating the need for continuous heating and incorporating a dielectric material to prevent scaling and dry fire failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tank of water is maintained at an elevated temperature continuously, then hot water is readily available for immediate dispensing, but thermal losses occur from external surfaces reducing operational energy efficiency
Solution Approach 1:
The system transitions from continuous heating to periodic/on-demand heating. The controller activates the heating element only when hot water is demanded, rather than maintaining continuous heat. This periodic operation eliminates standby thermal losses while ensuring hot water availability when needed, directly resolving the contradiction between readiness and energy efficiency.
2Power
If an electrical resistance heating element is used to heat water, then heating is effective and controllable, but scaling occurs on the heating surface reducing efficiency and causing premature failure
Solution Approach 1:
The patent replaces the traditional electrical resistance heating element with an ultrasonic heating element. This substitution changes the heating mechanism from resistive heating to ultrasonic cavitation heating, which occurs throughout the water volume rather than at a surface contact point. This eliminates the scaling problem that plagues resistance heating elements while maintaining effective heating capability.
3Power
If an electrical resistance heating element is used, then heating can be precisely controlled, but dry fire failures occur when the heating element is heated in the absence of water
Solution Approach 1:
The ultrasonic heating element replaces the electrical resistance heating element, fundamentally changing how heating is achieved. Ultrasonic elements generate heat through cavitation in the liquid itself rather than through direct resistive heating of contact surfaces. This eliminates the dry-fire failure mode because the ultrasonic element does not rely on water contact for heat transfer in the same way resistance elements do, and the system design ensures water is present before heating begins.
4Loss of energy
If water is heated rapidly on demand, then energy efficiency is improved by eliminating standby losses, but sufficient quantities must be heated quickly to keep up with demand
Solution Approach 1:
The system employs dynamic control where the heating element power and duration are adjusted based on real-time demand conditions. The controller monitors dispensing requirements and activates heating only for the necessary duration and intensity to meet immediate demand. This dynamic operation allows rapid heating of sufficient quantities while maintaining energy efficiency by avoiding unnecessary heating.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides hot water efficiently with minimal thermal losses, no scaling, and no dry fire failures, ensuring consistent temperature and flow rate without stagnation.
Implementation Method 1
The liquid heater assembly may include an array of electrodes positioned along the fluidic path, with adjacent electrodes defining two of the walls of each fluidic path
Implementation Method 2
The liquid heater assembly may include a structure defining one or more, tortuous, e.g., serpentine, spiral, etc., fluidic paths therethrough
Data Source
AI summary
An ohmic heater for the heating of a conductive fluid is comprised of a number of selectable electrodes, arrayed in such a way as to form a single pass-through from inlet to outlet. A series of flow conduits are provided to direct the flow across the faces of adjacent electrodes. The flow conduits are further configured such that the flow path makes multiple passes across the same adjacent set of electrode faces.